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Foldcraft ’ s Lean Journey

Foldcraft ’ s Lean Journey. Brian Kopas Vice President of Operations Foldcraft Company. Company Overview. Founded in 1948 100% Employee Owned since 1991. 215 Employees Trade Name Plymold 3 Mfg Locations: Kenyon MN (325,000 sq ft) Bloomington MN (50,000 sq ft)

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Foldcraft ’ s Lean Journey

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  1. Foldcraft’s Lean Journey Brian Kopas Vice President of Operations Foldcraft Company

  2. Company Overview • Founded in 1948 • 100% Employee Owned since 1991. • 215 Employees • Trade Name Plymold • 3 Mfg Locations: • Kenyon MN (325,000 sq ft) • Bloomington MN (50,000 sq ft) • Corona CA (17,000 sq ft)

  3. What Does Foldcraft Do? “We help our customers fulfill their brand image.”

  4. Some of Our Customers…

  5. Foldcraft’s Lean Journey YTD through 11/96, Pella conducted 762 events… Overall productivity has increased by 45% since ‘93… Delivering an 8%-10% improvement per year… 60% reduction in order-shipment lead-time WIP reduction of 50%.” Industry Week publishes “Kaizen Blitz” 9/97

  6. Industry Week publishes “Kaizen Blitz” 9/97 1st Foldcraft Shopfloor Event 8/98 Participate in Pella Event 6/98 Pella Visit 5/98 Foldcraft’s Lean Journey

  7. Foldcraft’s Lean Journey 1st Foldcraft Kaizen Event Results: 25% Productivity Increase. 66% WIP Reduction. 50% Floorspace Reduction. Knew enough to be dangerous! Recognized the need for expert guidance.

  8. FoldcraftEngages TBM 12/98 Foldcraft’s Lean Journey Industry Week prints “Kaizen Blitz” 9/97 1st Foldcraft Shopfloor Event 8/98 Participate in Pella Event 6/98 Pella Visit 5/98

  9. 1st Event With TBM 1/99 Foldcraft’s Lean Journey

  10. Foldcraft’s Lean Journey Table Manufacturing/Laminating Process: Heartbeat of our business. We thought many events over months, TBM said “One!” Worked round-the-clock to move major equipment. 2 Teams (24 team members, 22 contractors, 10 maintenance personnel & countless others). Results were stunning!

  11. 1st Business Process Event 1/00 Foldcraft’s Lean Journey 1st Event With TBM 1/99

  12. Foldcraft’s Lean Journey Quote and Order Processing: Could mfg faster than we could enter the order! Much “harder” than Mfg events. Mfg more accustomed to measurement, change. Greater potential for improvement in the office.

  13. 1st Policy Deployment Event 7/00 Foldcraft’s Lean Journey 1st Business Process Event 1st Event With TBM 1/99 1/00

  14. Policy Deployment Example “HOW” Breakthrough Thinking “HOW MUCH”

  15. Created “Process Build” 7/02 Foldcraft’s Lean Journey

  16. Foldcraft’sLean Journey Process Build: • A team of five dedicated to building “lean” equipment and supporting our Kaizen effort. Incorporates unique to us safety, quality and productivity enhancing features into our processes. • Develops new “lean” processes in support of product development. “Free up the best to help the rest!”

  17. Created “Process Build” 1st use of Lean Product Development 7/02 11/02 Foldcraft’sLean Journey

  18. Concept Development Voice of the Customer Foldcraft’s Lean Journey $ Lean Product Development Elements Launch Production Preparation Product Design Idea

  19. Launched Daily Walk Through 1/05 Foldcraft’s Lean Journey

  20. Daily Walk-Through: Plan - Annual Goals “Deployed” to each cell. Do - Daily Cell Operation & Plan Implementation. • Check - Operations leadership visits the cells every day to review performance. - 1 hr. commitment daily. - Cell Supervisors present performance. • Act – Kaizen Newspaper Items. - Action items are assigned to specific individuals or support resources such as Engineering, Maint, and Process Build. - Open action status is reviewed during walk-through.

  21. Managing Hour x Hour

  22. Safety Quality Delivery Cost SQDC Performance Board

  23. SQDC Charts – Daily Results

  24. SQDC Charts – 13 Week Trend

  25. SQDC Charts – Pareto

  26. SQDC Charts – Newspaper - Actions

  27. New 1st line leadership to drive MDI Launched Daily Walk Through 1/05 5/05 Foldcraft’s Lean Journey

  28. Managing For Daily Improvement • Focusing on every process cycle to insure we do it with the right Safety, Quality and Cost the 1st time, every-time. • Focusing on making the next cycle better than the previous by eliminating waste and Abnormalities. Fixing it Today vs. collecting data to fix it tomorrow .

  29. Foldcraft’s Lean Journey • Managing for Daily Improvement (MDI) by eliminating waste and abnormalities is an expectation of all management. Two of these trend lines are unacceptable!

  30. New 1st line leadership to drive MDI Hands On Training Lab Created Launched Daily Walk Through 1/05 5/05 4/06 Foldcraft’s Lean Journey

  31. Information Application Integration Hands On Training Lab First week in the life of ALL new employees. Introduction to FC culture, customers, strategies. • Provides understanding of FC business concepts -Lean, Kaizen, Standard Work, products. Safety, Safety, Safety! Demonstrates that “We’re glad you’re here!”

  32. Self Directed Work Teams Created New 1st line leadership to drive MDI Hands On Training Lab Created Launched Daily Walk Through 1/05 5/05 4/06 6/09 Foldcraft’s Lean Journey

  33. Self Directed Work Teams Mfg processes were working in flow, business processes were not. Traditional dept. and leadership structure created bottlenecks and barriers to flow. Depts were groups of individuals, each working to please their manager vs. teams working to please their customer. Requires a transition from holding people accountable to people being accountable!

  34. Mfg Lead-Time 66% Floorspace 50,000 sq. ft. Productivity 240% Claims 48% On-Time 95.2% 99.3%+ Results Achieved ‘98-Present: >30% of sales today are from in-sourced or new items. Barely scratching the surface!!

  35. Results Achieved A Major Customer Example: Nearly 62,000 shipments from ’00 – ‘11. Only 32 late shipments. That’s 99.95% on-time performance!

  36. Key Lessons Learned: The success of the journey is directly linked to the authority and commitment of its champion. Utilize an outside Sensei to speed progress, leverage a network of others on the journey, and to see-through organizational blind spots. It’s not about tools…It’s about people. Have patience and perseverance for the journey. The further you travel, the more you’ll recognize the distance to be traveled.

  37. Foldcraft’s Lean Journey Thank You!!

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